Tuesday, Sep 03, 2002 at 00:00
John F, it was obvious to me after my experience that thebdesign of the front
suspension is suspect.
1. the "rolled over" trapping of the lower ball joint carries the full corner weigth to the lower wishbone then the spring -shocker.
Rollover production operation is not so easy to maintain optimum and thus strength will vary, despite Toyota Total Quality Control and Process statistical Controls.
A safer design would use a two piece housing with a machined lower portion bolted to a revised machined upper section thus trapping the ball and with thicker metal at the base to give a longer wear life.
Also, the press fit of the upper ball joint does not allow replacement in the bush. You need a 5 tonne press!!
The
suspension member needs redesign to chage the upper ball joint to a bolt on design that is readily replaced by any maechanic using spanners and at most a ball-joint wedge.
PS I worked in the automotive componets industry as a designer production engineer amd manager for 27 years. We supplied all Toyota steering columns,
suspension links and brake drums and discs.
Toyota are usually very conservative designers. Not so here.
My failure and one of two Surf KZN-1185 failures I have seen WERE NOT DUE TO SEAL FAILURE AND LOSS OF LUBRICATION.... THESE TWO WERE JUST DIRECT DISLOCATIONS OF THE BALL JOINTS.
Rubber seals were intact and joints were fully greased.
My car did have a front impact prior to my purchase that may have stressed the lower joint but this could not be detected and the joint had no looseness, the Surf-185 had no prior damage.
IF you need support in your case I can assist.
Regards, J. Rory Thompson
MIEAust. CPEng. 2180308
B.Tech. Mech. A (University of
Adelaide 1967)
M. Eng. Sc's. Materials Welding & Joining (U of A 1999)
I am a Chartered Professional Engineer, consult in the auto industry and design and build sports cars.
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